System and method for facilitating well construction

ABSTRACT

A technique is provided to limit the number of vehicles required during a well project involving a plurality of well construction related procedures. The technique utilizes a modular unit, e.g. a vehicle, and a plurality of modules that may be interchanged on the modular unit according to the scheduled well procedure. A separate crane unit can be used to move the modules to and from the vehicle as required for specific phases of well construction.

CROSS-REFERENCE TO RELATED APPLICATION

This application claims priority as a divisional application of U.S.patent application Ser. No. 11/132,568, filed May 19, 2005, entitledSYSTEM AND METHOD FOR FACILITATING WELL CONSTRUCTION, which is herebyincorporated by reference in its entirety.

BACKGROUND

In well construction projects, numerous well related vehicles andequipment are required for various well construction procedures. Forexample, cementing applications, such as placing a casing or a liner ina wellbore, involve cementing the casing or liner to the inner wall ofthe wellbore. Cement is mixed at a surface location and pumped into thewellbore as cement slurry. The cement slurry is flowed into an annularregion between the outside of the casing or liner and the inner wall ofthe wellbore. The slurry is mixed at the well surface via cement mixingequipment carried on a truck or trucks, which are used to move thecement mixing and pumping equipment to multiple well sites requiringsuch services.

Other well construction procedures, such as openhole logging and acidtreatment procedures, are performed with separate equipment carried byseparate vehicles. For example, a wireline truck is used to carry thewireline equipment, and an acid pumping truck is used to carry equipmentfor the acid treatment procedure. Each of these trucks and equipmentrequires a separate crew to carry out the specific well constructionrelated procedure. By way of example, a well construction projectinvolving a cementing procedure, acid treatment procedure and wirelineprocedure can require five separate equipment carrying trucks plussupporting pickup trucks. The many separate trucks and separate crewscan create inefficiencies in scheduling, dispatching, road travel,project cost and other factors affecting well construction projects.

SUMMARY

In general, the present invention provides a system and method offacilitating well construction and reducing inefficiencies inperformance of well construction related services. The system and methodutilize a vehicle having a cement pumping unit for cementing proceduresand a mounting unit for selectively receiving modules related to otherwell construction procedures. A plurality of modules, specificallydesigned for unique phases of the well construction project, can besequentially mounted to the mounting unit enabling the use of a singlevehicle in the performance of a plurality of well related procedures.

BRIEF DESCRIPTION OF THE DRAWINGS

Certain embodiments of the invention will hereafter be described withreference to the accompanying drawings, wherein like reference numeralsdenote like elements, and:

FIG. 1 is a schematic top view of a well site with components tofacilitate well construction, according to an embodiment of the presentinvention;

FIG. 2 is a side view of a vehicle having a mounting unit for receivinginterchangeable modules, according to an embodiment of the presentinvention;

FIG. 3 is a side view of the vehicle illustrated in FIG. 2 with a cementbulk module attached, according to an embodiment of the presentinvention;

FIG. 4 is a side view of the vehicle illustrated in FIG. 2 with awireline module attached, according to an embodiment of the presentinvention;

FIG. 5 is a side view of the vehicle illustrated in FIG. 2 with an acidbulk module attached, according to an embodiment of the presentinvention;

FIG. 6 is a schematic illustration of the vehicle illustrated in FIG. 2with a control system, according to an embodiment of the presentinvention; and

FIG. 7 is a crane vehicle that may be used with the system illustratedin FIG. 1.

DETAILED DESCRIPTION

In the following description, numerous details are set forth to providean understanding of the present invention. However, it will beunderstood by those of ordinary skill in the art that the presentinvention may be practiced without these details and that numerousvariations or modifications from the described embodiments may bepossible.

The present invention generally relates to well construction projects inwhich various well procedures, e.g. services, are performed. Theefficiency of well construction is enhanced by providing the capabilityof performing multiple well construction related procedures with areduced number of equipment carrying vehicles. The system also enables areduction in the number of crew members while providing easytransportability of equipment from one well site to another.

Efficiency of well construction is enhanced, at least in part, by amodular unit that can handle specific aspects of a well constructionprocess before being reconfigured for subsequent well constructionrelated procedures. The single modular unit may be designed, forexample, to handle cementing processes, such as the cementing of casingsor liners in a wellbore while being readily reconfigurable forsubsequent well construction procedures, such as acid injectionapplications and logging/wireline processes.

Referring generally to FIG. 1, a top view of a well site 20 isillustrated. In this example, a well 22 is undergoing well constructionprocedures and generally comprises wellbore 24 extending downwardly froma wellhead 26 into a subterranean formation containing desiredproduction fluids, such as hydrocarbon based fluids. In many projects,wellbore 24 is drilled into an oil bearing formation for the productionof oil. Additionally, only one well 22 is illustrated, but a givenproject may comprise multiple wells that undergo various wellconstruction related procedures. It also should be noted that certainwell construction procedures can be performed on new or existing wells.

As illustrated in FIG. 1, a modular unit 28 is provided at well site 20for the performance of a plurality of well construction relatedprocedures. Modular unit 28 comprises a vehicle 30 that may be movedaround well site 20 or from one well site to another. In thisembodiment, vehicle 30 is a road legal truck that may be driven from onewell site to another or from one well project to another over the publicroad system of the region.

In the example illustrated, vehicle 30 comprises a well constructionequipment region 32 and a mounting unit 34. Well construction equipmentregion 32 may be designed to receive a fixed cement pumping unit 36, andmounting unit 34 is designed to interchangeably receive a plurality ofmodules, e.g. modules 38, 40 and 42. The modules are selectively mountedto mounting unit 34 via a mounting mechanism 44 that enables the easyconnection and disconnection of each module for facilitating a specificunique phase of well construction. The series of modules may be mountedto mounting unit 34, sequentially, to facilitate the sequential phasesof well construction. A given module typically is designed for aspecific phase of the well project, e.g. cementing, acid application,logging. Mounting mechanism 44 can comprise a variety of designs,including mechanical catch and release mechanisms, fasteners, e.g.bolts, hydraulically actuated locks or other mechanisms that enable therelatively rapid mounting of the module, disconnection of the module,and mounting of a subsequent module according to the well constructionprocedures for a given project.

Modules 38, 40 and 42 may be sequentially mounted and disconnected frommounting unit 34 with the aid of a crane unit 46. Crane unit 46comprises a boom 48 used to move a given module to or from mounting unit34. For example, crane unit 46 can be connected to module 38 uponcompletion of a well construction related procedure. Module 38 is thenlifted to a storage location, and module 40 is moved to mounting unit 34and secured. Upon completion of the second well related procedure, craneunit 46 can be used to move module 40 to storage, and module 42 is movedinto position on mounting unit 34. Accordingly, a variety of wellconstruction related procedures can be carried out sequentially with acombined use of vehicle 30 and crane unit 46. In some applications,alternate or additional modules can be used for other well relatedprocedures.

Crane unit 46 may comprise a stand alone crane positioned at well site20. Alternatively, however, crane unit 46 may comprise a vehicle 48,such as a road legal vehicle. In this latter example, vehicle 48 maycomprise a load carrying region 50 sized to carry one or more of themodules 38, 40 or 42. In a specific example, load carrying region 50 issized to carry two modules, thus enabling the transport of three modules(one on vehicle 30 and two on vehicle 48) to each well site.

An embodiment of vehicle 30 is illustrated in FIG. 2. In thisembodiment, vehicle 30 is a road legal truck having a chassis 52supported on front wheels 54 and rear wheels 56. As illustrated, rearwheels 56 are mounted on a pair of axles. However, vehicle 30 maycomprise a single rear axle or multiple rear axles depending on theweight of the equipment carried as well as the regional regulationspertaining to use of vehicles on public roadways.

A cab 58 is mounted on chassis 52 and may comprise an extended or doublecab region 60 to provide room for carrying, for example, control systemequipment, as discussed below. Cement pumping unit 36 also is mounted onchassis 52 to the rear of cab 58. In this example, the cement pumpingunit 36 is mounted to the chassis by a platform 62 that provides anequipment supporting surface. Chassis 52 extends rearwardly of cementpumping unit 36 to provide space for mounting unit 34.

Various equipment configurations may be mounted at well constructionequipment region 32 depending on the specific well procedures for whichthe vehicle is designed. In the example illustrated, however, cementpumping unit 36 comprises cement mixing and pumping equipment 64 and areel and hose assembly 66. An example of the equipment that may bemounted at the well construction equipment region 32 of vehicle 30 isthe cement mixing and pumping equipment found on the CemSTREAK® pumpertruck available from Schlumberger. In this example, the CemSTREAK®cement mixing and pumping equipment 64 has several inlets for receivingmaterials, such as inlets 68 for receiving water and inlets 70 forreceiving particulate material, e.g. cement in powder form. Theequipment further includes a reservoir 72, such as a pair of reservoirs,coupled to a cement mixer 74. A pair of reservoirs may be used asdisplacement tanks and, in some embodiments, at least one of thereservoirs can be used as a mixing tank to mix cement, water andadditive to form the cement slurry. The cement slurry is pumped intowellbore 24 by a pumping 76 that moves the slurry through the hose ofreel and hose assembly 66. Pump 76 is positioned generally between thereservoir/displacement tank 72 and cab 58. Other components may comprisea flowmeter 78 for monitoring the flow of cement slurry and a controlconsole 80 that may be used by an operator to control the mixing andpumping of cement slurry.

In the embodiment illustrated in FIG. 2, cement pumping unit 36 providesmixing and pumping capabilities for well construction cementingprocedures. However, other well construction processes are handled bymodules selectively mounted to mounting unit 34, as opposed to usingseparate vehicles to perform these additional well related functions. Asillustrated in FIG. 3, for example, module 38 may comprise a module forsupplying bulk material to cement mixing and pumping equipment 64.Cement bulk module 38 comprises a bulk material holding tank 82 mountedon a support framework 84 that may be readily connected and disconnectedfrom mounting unit 34 via mounting mechanism 44. Instead of supplyingbulk material via a separate truck, module 38 is simply mounted tomounting unit 34 during the cement mixing and pumping phases of wellconstruction. Upon completion of the cementing process, module 38 may bedisconnected and removed from mounting unit 34 to enable theinterchanging of module 38 with another module.

As illustrated in FIG. 4, another module, such as module 40, is readilyinterchanged with module 38. In this example, module 40 comprises awireline module having, for example, a wireline 86 and a wireline winch88 for moving the wireline into wellbore 24. Wireline module 48 can beused for a variety of well construction related procedures, includingthe logging of data from within the well. Upon completion of this phaseof well construction, module 40 is released from mounting unit 34 toenable the interchanging of another module, such as module 42.

Referring generally to FIG. 5, vehicle 30 is illustrated with module 42interchanged for module 40. In this example, module 42 comprises an acidbulk module having an acid tank 90 for holding acid that is used in acidtreatment procedures within well 22. Again, upon completion of the acidtreatment procedure, module 42 can be disconnected to enableinterchanging with another module. If the well project is completed, themodule can be left mounted at mounting unit 34 for transport to anotherlocation. It should be noted that the modules and the process orderdiscussed above are used simply to demonstrate the modularinterchangeability that promotes desired efficiencies in wellconstruction. The actual number of modules, functionality of themodules, and the sequence of interchanging modules can vary depending onthe specific well project for which vehicle 30 is utilized.

In the embodiment illustrated in FIG. 6, a control system 92 is locatedwithin cab 58. Control system 92 is operatively coupled to cement mixingand pumping equipment 64 via a communication line 94 that enablescontrol of the cementing process from within cab 58. Control system 92also may be operatively coupled to selected modules, such as module 40,via a communication line 96. In this example, control system 92 iscoupled to wireline module 40 to enable control of the wireline processfrom within cab 58. Accordingly, control over cementing procedures andother procedures enabled by specific modules, e.g. wireline procedures,all may be controlled by an operator from within the cab of the vehicle.Communication of data via communication lines 94 and 96 may beaccomplished by a variety of communication techniques, hardware andprotocols. For example, communication lines 94 and 96 may be hardwiredcommunication lines, wireless communication lines or fluid communicationlines.

Referring generally to FIG. 7, one embodiment of crane unit 46 isillustrated. In this embodiment, the crane unit is formed as vehicle 48.Vehicle 48 may be a road legal truck having a chassis 98 supported onfront wheels 100 and rear wheels 102. As illustrated, rear wheels 102are mounted on four axles. However, vehicle 48 may comprise othernumbers of rear axles depending on the weight of the equipment carriedas well as the regional regulations pertaining to use of vehicles onpublic roadways.

A cab 104 is mounted on chassis 98, and a crane 106 also is mounted onchassis 98 via a platform 108. In this embodiment, crane 106 is mountedtowards the rear of vehicle 48 and comprises a boom 108 used to lift andmove modules to and from mounting unit 34 of vehicle 30. A plurality ofstabilizer mechanisms 110, such as hydraulic stabilizer arms, can bepressed against the ground to stabilize platform 108 during movement ofmodules with crane 106. Additionally, this embodiment of vehicle 48 alsofacilitates the storage of at least one module at load carrying region50. In the specific embodiment illustrated, load carrying region 50 islocated on platform 108 between the base of crane 106 and cab 104 and issized to carry two modules, such as module 38 and module 40. With thisoverall system design, three separate modules can be moved from one wellsite to another with one module mounted on mounting unit 34 of vehicle30 and two modules mounted on load carrying region 50 of vehicle 48.

In operation, a cement mixing and pumping unit may be mounted on a roadlegal vehicle along with a module mounting unit for receiving modulesrelated to specific well construction procedures. At each well site, themodules are readily interchanged with the aid of crane unit 46 which isdesigned to remove a given module from mounting unit 34, move thatmodule to a separate location, attach and lift a different module fromload carrying region 50 or other location, and move the new module intoengagement with mounting unit 34 of vehicle 30. This process can berepeated for each well related procedure until the well project iscompleted. If crane unit 46 comprises vehicle 48, the modules then cansimply be loaded on vehicles 30 and 48 and moved to the next well site.Thus, the system and method described above enables one or two vehicleslocated at a well site to perform multiple procedures by interchangingmodules, e.g. modules 38, 40 and 42, on modular unit 28. The specificmodules and the sequence of interchanging is selected according to thespecific procedures desired for a given well project.

It should be noted that modular unit 28 may be constructed in a varietyof configurations of fixed and reconfigurable functionality. Forexample, other permanent equipment for different types of procedures canbe used instead of cement mixing and pumping equipment 64. Additionally,the size and functionality of the modules described above can be changedor adjusted.

Accordingly, although only a few embodiments of the present inventionhave been described in detail above, those of ordinary skill in the artwill readily appreciate that many modifications are possible withoutmaterially departing from the teachings of this invention. Accordingly,such modifications are intended to be included within the scope of thisinvention as defined in the claims.

1. A system for reducing the number of oilfield equipment carryingvehicles comprising: a first road legal truck comprising a cementpumping unit and a first mounting region, wherein a firstinterchangeable well process module is mounted on said first mountingregion; a second road legal truck comprising a crane, a second mountingregion, and a third mounting region, wherein a second interchangeablewell process module is mounted on said second mounting region and athird interchangeable well process module is mounted on said thirdmounting region; wherein each of said first interchangeable well processmodule, second interchangeable well process module, and thirdinterchangeable well process module is configured to be interchangeablymounted on one of said first mounting region, said second mountingregion, and said third mounting region; and wherein said firstinterchangeable well process module, said second interchangeable wellprocess module, and said third interchangeable well process module areconfigured to perform different oilfield operations; and wherein saidfirst interchangeable well process module, said second interchangeablewell process module, and said third interchangeable well process moduleare configured to be controlled by a control system located in the firstroad legal truck or the second road legal truck.
 2. The system of claim1, wherein each of said first interchangeable well process module,second interchangeable well process module, and third interchangeablewell process module comprises one of a cement bulk module, an acid bulkmodule, and a wireline module.
 3. The system of claim 1, wherein each ofthe first road legal truck and the second road legal truck comprises avehicle cab.
 4. The system of claim 1, further comprising a controlsystem located in the first road legal truck or the second road legaltruck, the control system being designed to control the differentoilfield operations.
 5. A system for facilitating well construction,comprising: a vehicle having a cement mixing and pumping unit forcementing operations and a mounting unit; a plurality of modules, eachmodule being designed for a unique phase of well construction, whereinthe plurality of modules are sequentially mountable to the mounting unitto facilitate the unique phase of well construction corresponding to agiven module; and a control system located in the vehicle, the controlsystem being design to control the unique phase of well constructioncorresponding to a given module.
 6. The system as recited in claim 5,wherein the plurality of modules comprises a cement bulk module.
 7. Thesystem as recited in claim 6, wherein the plurality of modules comprisesa wireline module.
 8. The system as recited in claim 6, wherein theplurality of modules comprises an acid bulk module.
 9. The system asrecited in claim 8, wherein the plurality of modules comprises awireline module.
 10. The system as recited in claim 5, wherein thevehicle comprises a road legal truck.
 11. The system as recited in claim10, wherein the mounting unit is located to the rear of the cementmixing and pumping unit.
 12. A method of reducing the number of vehiclesat a well site during a well construction, comprising: mounting a cementpumping unit and an interchangeable well process module on a truck;utilizing a crane mounted on a crane truck to switch the interchangeablewell process module with another well process module that is designed tofacilitate a subsequent stage of the well construction; and controllingthe cement pumping unit and the interchangeable well process module witha control system located on the truck.
 13. The method as recited inclaim 12, wherein mounting comprises mounting the interchangeable wellprocess module to a mounting unit positioned on the truck to the rear ofthe cement pumping unit.
 14. The method as recited in claim 12, whereinutilizing comprises switching a cement bulk module and a wirelinemodule.
 15. The method as recited in claim 12, wherein utilizingcomprises switching a cement bulk module and an acid bulk module. 16.The method as recited in claim 12, wherein utilizing comprises switchinga wireline module and an acid bulk module.
 17. The method as recited inclaim 12, further comprising storing at least two interchangeable wellprocess modules on the crane truck for use on the truck during otherstages of well construction.